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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 947 (Engine Controls - 4.8L, 5.3L, & 6.0L (Introduction)) >> Repair Instructions >> Fuel Tank Replacement (Cab/Chassis - Front) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. If necessary, install the sending unit. Refer to Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)  or Fuel Sender Assembly Replacement (5.3L (L59) Engine) .
  2. Remove the caps from the fuel and EVAP pipes.
  3. With the aid of an assistant, place the fuel tank on the jack.
  4. Raise the fuel tank.
  5. Install the fuel tank straps.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the fuel tank strap bolts.

    Tighten:  Tighten the bolts to 40 N.m (30 lb ft).

    7. Fig 1: Fuel Tank, Strap & Bolts (Cab/Chassis - Front)
    GM1228169Courtesy of GENERAL MOTORS CORP.
  7. Remove the jack from under the fuel tank.
  8. Install the fuel tank shield.
  9. Install the fuel tank shield bolts.

    Tighten:  Tighten the bolts to 18 N.m (13 lb ft).

    10. Fig 2: Fuel Tank Shield & Bolts (Cab/Chassis - Front)
    GM877744Courtesy of GENERAL MOTORS CORP.
  10. Lower the vehicle.
  11. Connect the fuel feed and EVAP quick connect fittings to the sending unit. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    12. Fig 3: Fuel Feed & EVAP Quick Connect Fittings At Sending Unit
    GM1228206Courtesy of GENERAL MOTORS CORP.
  12. Connect the fuel sending unit and fuel pressure sensor electrical connectors (1).
    13. Fig 4: Fuel Pressure Sensor Electrical Connector & Fuel Sending Unit Electrical Connector
    GM1238183Courtesy of GENERAL MOTORS CORP.
  13. Install the CVS line to the fuel tank clips.
  14. Install the fuel fill pipe and vent pipe to the tank.
  15. Tighten the vent pipe clamp (1) at the tank.
  16. Tighten the fuel fill pipe clamp (2) at the tank.

    Tighten:  Tighten the clamps to 2.5 N.m (22 lb in).

    17. Fig 5: View Of Fuel Fill Pipe Clamp & Vent Pipe Clamp
    GM1228174Courtesy of GENERAL MOTORS CORP.
  17. Remove the caps from the fuel feed and EVAP pipes.
  18. If equipped with a rear auxiliary tank, connect the fuel feed and EVAP quick connect fittings. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  19. Refill the fuel tank.
    20. Fig 6: View Of Fuel Feed And Pressure Balance Lines
    GM1228187Courtesy of GENERAL MOTORS CORP.
  20. Install the fuel fill cap.
  21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) .
  22. Perform the following steps in order to inspect for leaks.
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2. Turn the ignition OFF for 10 seconds.
    3. Turn the ignition ON, with the engine OFF.
    4. Inspect for fuel leaks.
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